Dover HEIL LIBERTY TP1L-SM-0520 Service Manual Download Page 96

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Issued May 2020
Body Controller Hardware

Printed in the U.S.A.

Body Controller Hardware

BODY CONTROLLER

The Body Controller is mounted inside the street side hoist cylinder bracket.

Mounted with the body controller are the relays that control the hoist raise/lower and tailgate raise/lower.

LED COLOR

STATUS

DESCRIPTION

N/A

OFF

No Supply Voltage

Red/Green

1 Flash

Initialization

Red/Green

Flash @ .5 Hz

Communications Lost

Green

Flash @ 5 Hz

No Operating System Loaded

Green

Flash @ 2 Hz

Application Running (RUN MODE)

Green

Continuous

Application Stop (STOP MODE)

Red

Flash @ 5 Hz

Supply Voltage Low

Red

Flash @ 10 Hz

Fatal Error

Figure 34. Body Controller Location

Figure 35. Body Controller

Summary of Contents for HEIL LIBERTY TP1L-SM-0520

Page 1: ...CONTINUOUS PACK AUTOMATED SIDE LOADER SERVICE MANUAL ISSUED MAY 2020 TP1L SM 0520 2020 Heil Environmental ...

Page 2: ...in the service manual It is also important to understand these warnings are not exhaustive Heil could not possibly know evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each method Consequently Heil has not undertaken any such broad evaluations Accordingly anyone who uses service procedures or tools which are ...

Page 3: ...s and Fittings 27 Cold Weather Warm Up Procedure 27 Battery Disconnect Switch 28 Proximity Switch Troubleshooting 32 Safety Decals on the Unit 32 Decal Care 34 Hydraulic Symbols 36 Electrical Symbols Pumps 38 Hydraulic Pump Control 39 Tandem O I G A I Pump 40 Tandem Vane Pump O I G A I Hydraulic System Troubleshooting Lift Arm 44 Nomenclature 45 Specifications 46 Python Lift Lubrication Guide 47 P...

Page 4: ...Hydraulic Oil Filter 84 Drain and Clean the Hydraulic Oil Tank 85 Purge the Hydraulic System 86 Packer Body Valve 87 Packer Body Valve Troubleshooting 88 Cracked Weld Joints 88 Oil Lubrication Recommendation 88 Grease Lubricant Recommendation 88 Tailgate Lubrication 88 Inspect Proximity Switches 88 Clean and Inspect the Tailgate Seal Body Controller Hardware 90 Body Controller 91 Control Fuses Bod...

Page 5: ...44 107 2018 Liberty International Chassis Electrical Schematic 112 701 8776 001 Lift Arm Up and In Flow Diagram 113 701 8776 002 Lift Arm Release Flow Diagram 114 701 8776 003 Lift Arm Grab Flow Diagram 115 701 8776 004 Lift Arm Reach In Flow Diagram 116 701 8776 005 Lift Arm Reach Out Flow Diagram 117 701 8776 006 Lift Arm Down Flow Diagram 118 701 8467 Hydraulic Schematic 119 701 8394 B Packer L...

Page 10: ...is section explains the system and its major components Diagrams and schematics of the electrical and hydraulic systems are in the Service Manual Schematics section NOTICE For CNG units this Service Manual should be used in conjunction with any associated CNG System Manufacturer s Operation and Maintenance Manuals Always read and understand all associated manuals alongside the Heil Parts and Servi...

Page 11: ...hooting repair and service is available by contacting the authorized Heil Dealer in your area Parts are available at your Heil Dealer or through Heil Heil personnel are trained to give prompt professional assistance ALWAYS give the unit serial number in all correspondence relating to the equipment See the back cover of this manual for Heil contact information ...

Page 12: ...43 BELT ARM 60 90 GAL 47 1 093 2784 BEARING RETAINMENT 4 003 4432 PIVOT BEARING 1 003 5083 BEARING 2X3 1 003 5084 BEARING 3X1 2 022 3922 SEAL BUSHING 2 2 018 0804 SPRING 1 HYDRAULICS 001 7003 CYLINDER PACKER 1 001 6991 CYLINDER TAILGATE 2 001 7069 CYLINDER LIFT AND REACH 2 001 6973 CYLINDER DUMP 1 001 7045 CYLINDER BODY HOIST 1 031 6194 VALVE BODY 1 031 6412 VALVE LOADER 1 031 2616 VALVE SHUT OFF ...

Page 13: ...PARTS PART NO DESCRIPTION QTY 063 0123 SWITCH PROXIMITY NO SOURCING 30MM 1 063 0115 SWITCH PRESSURE W CONNECTOR PACKARD 1 069 0032 KIT MICRO RELAY 2 108 5031 WHISKER SWITCH 1 CONTROLS 031 6254 JOYSTICK PNEUMATIC 3 PUSH BUTTONS 1 075 0953 012 SWITCH ELECTRICAL FILTER RETURN LINE 1 108 2280 RUBBER BOOT 4000 2 108 6422 SWITCH TOGGLE 2 ...

Page 14: ...Keyword s or Part Number and or Heil Body Serial Number to quickly identify a spare part or browse a custom parts catalog Note This tool is currently for reference use only and the cart functionality is disabled Please contact your local Heil Dealer for parts quoting and ordering Registration and Login Register online to gain access https epc partscentral com Upon registration you will receive an ...

Page 15: ...ng for a proximity switch for Body Serial Number HPS4959991 you can enter this information into these two fields and the search results will include all parts within the HPS4959991 body that contain the keywords proximity and switch within their part descriptions See the image below From the search results list you can select the right arrow icon to view the part within its associated assembly kit...

Page 16: ...amiliar catalog sections that you can browse You can navigate through the catalog using the section topic menu in the left panel and then adjust an assembly kit illustration size in the right panel with the mouse center scroll wheel Additionally in the right panel you can drag the image when holding down the left mouse button See the image below For each assembly kit you can click on the interacti...

Page 17: ...nd or damage to property Do not operate this vehicle before you read and understand the Operation Manual the Parts Service Manual for this unit other applicable manufacturer s manuals and the safety decals on the product Each operator of this unit must read and understand all directions in this manual before they first operate this vehicle Keep this manual in the cab for new operators and to remin...

Page 18: ...ing capability and clear ALL persons not involved with the procedure away from the area DANGER The lifting equipment can fail Serious injury or death can occur if the lifting equipment breaks and the body falls or the unit rolls over Do not place your body or limbs between the unit s body and chassis while you remove the body supporting timbers Be attentive and prepared to move quickly away from t...

Page 19: ...le and is harmful to eyes and skin Keep isopropyl alcohol away from heat or open sources of ignition Flush eyes and skin with water for 15 minutes after contact Seek immediate medical help WARNING A container that is not locked to the container lift mechanism is dangerous The container can fall off the container lift mechanism and cause death or serious injury Make sure you engage and lock the con...

Page 20: ...h pressure with the grabber to raise the container with the lift arm and not damage the container NOTICE Always use your employer s Lock Out Tag Out procedures If your employer does not have Lock Out Tag Out procedures use the procedures that follow Contact your supervisor or ESG Technical Service if you have any questions about Lock Out Tag Out procedures NOTICE You can order Lock Out Tag Out Tag...

Page 21: ...g Out Do Not Operate Tag Follow These Steps 1 APPLY the brakes MAKE SURE the brakes do not let the unit move and they work properly 2 Chock all wheels 3 SET the tailgate props when you raise the tailgate for service maintenance or cleaning 4 SET the body props when you raise the body for service maintenance or cleaning 5 When there are in cab controls turn the ignition switch to ON then a Move the...

Page 22: ...decal on the unit and in the Body Lubrication Guide paragraph of this section Use grade NLG1000 grease or equivalent OIL LUBRICANT RECOMMENDATION Use only non detergent engine oil to lubricate all moveable mechanical parts not furnished with grease fittings Apply sufficient oil to give good lubrication but do not bathe parts in oil Always wipe off excess oil HYDRAULIC OIL SPECIFICATIONS Hydraulic ...

Page 23: ... SAE 30 engine oil See notice above Joints are rigid that is no gaskets or compressible materials are used When re using nuts or bolts use minimum torque values STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Bolt Size D Nut Type STD Lock Thread Turns per Inch p Grade Heil Plain Dry Condition Torque Value ft lbs Heil Zinc Plated Fastener Torque Value ft lbs Heil Lubricated Fastener Torque Value ft l...

Page 24: ...ue ft lbs Heil Lubricated Fastener Torque Value ft lbs Heil Deformed Lock Nut Torque Value ft lbs 24 5 25 8 35 7 16 STD 14 5 53 48 35 4375 8 76 68 49 20 5 60 54 39 8 84 76 55 Lock 14 5 35 8 49 20 5 39 8 55 1 2 STD 13 5 82 73 53 500 8 115 104 75 20 5 92 83 60 8 130 117 84 Lock 13 5 53 8 75 20 5 60 8 84 9 16 STD 12 5 118 106 77 5625 8 166 150 108 18 5 131 118 85 8 186 167 121 Lock 12 5 77 8 108 18 5...

Page 25: ...ated Fastener Torque Value ft lbs Heil Deformed Lock Nut Torque Value ft lbs 18 5 120 8 169 3 4 STD 10 5 288 260 188 0 750 8 408 367 265 16 5 322 290 209 8 455 409 295 Lock 10 5 188 8 265 16 5 209 8 295 7 8 STD 9 5 465 418 302 0 8750 8 657 591 427 14 5 513 461 333 8 724 652 471 Lock 9 5 302 8 427 14 5 333 8 471 1 STD 8 5 697 627 453 1 0000 8 984 886 640 14 5 782 704 508 8 1105 994 718 Lock 8 5 453...

Page 26: ...e Value ft lbs Heil Lubricated Fastener Torque Value ft lbs Heil Deformed Lock Nut Torque Value ft lbs 12 5 634 8 1017 1 1 4 STD 7 5 1227 1104 797 1 2500 8 1969 1772 1280 12 5 1358 1222 883 8 2179 1961 1417 Lock 7 5 797 8 1280 12 5 883 8 1417 1 3 8 STD 6 5 1608 1447 1045 1 3750 8 2580 2322 1677 12 5 1830 1647 1190 8 2938 2644 1909 Lock 6 5 1045 8 1677 12 5 1190 8 1909 1 1 2 STD 6 5 2134 1921 1387 ...

Page 27: ...TYPE IDENTIFICATION CHART IH Type S A E Grade Description Bolt Head Marking 1 1 or 2 No radial lines Low or medium carbon steel not heat treated NOT USED replace with same grade bolt 5 5 Three radial lines Quenched and tempered medium carbon steel 8 8 Six radial lines Quenched and tempered special carbon or alloy steel ...

Page 28: ...AT FACE ORFS FITTINGS SET WRENCH TO NOMINAL TUBE OD TORQUE WRENCH SETTING ALTERNATE TORQUE UNITS 1 4 21 ft lbs 250 in lbs 3 8 33 5 ft lbs 400 in lbs 1 2 50 ft lbs 600 in lbs 5 8 50 ft lbs 600 in lbs 3 4 75 ft lbs 900 in lbs 1 105 ft lbs 1260 in lbs 1 1 4 130 ft lbs 1560 in lbs 1 1 2 178 5 ft lbs 2140 in lbs Figure 2 Torque for Hydraulic Tubes and Fittings ...

Page 29: ...WRENCH SETTING ALTERNATE TORQUE UNITS 1 8 6 5 ft lbs 80 in lbs 3 16 9 ft lbs 110 in lbs 1 4 12 5 ft lbs 150 in lbs 5 16 16 5 ft lbs 200 in lbs 3 8 21 ft lbs 250 in lbs 1 2 41 ft lbs 490 in lbs 5 8 64 ft lbs 770 in lbs 3 4 89 ft lbs 1070 in lbs 7 8 105 ft lbs 1260 in lbs 1 130 ft lbs 1560 in lbs 1 1 4 142 5 ft lbs 1710 in lbs 1 1 2 178 5 ft lbs 2140 in lbs 2 250 ft lbs 3000 in lbs Figure 3 Torque f...

Page 30: ...1 ft lbs 250 in lbs 3 8 29 ft lbs 350 in lbs 1 2 64 ft lbs 770 in lbs 5 8 89 ft lbs 1070 in lbs 3 4 130 ft lbs 1560 in lbs 7 8 178 5 ft lbs 2140 in lbs 1 224 ft lbs 2690 in lbs 1 1 4 250 ft lbs 3000 in lbs 1 1 2 300 ft lbs 3600 in lbs ALUMINUM SET TORQUE WRENCH SETTING ALTERNATE TORQUE UNITS 6 ft lbs 70 in lbs 11 ft lbs 130 in lbs 14 ft lbs 170 in lbs 21 ft lbs 250 in lbs 37 5 ft lbs 450 in lbs 54...

Page 31: ...LUMINUM FT LBS IN LBS 1 2 5 16 18 x 1 25 17 ft lbs 200 in lbs 12 130 3 4 3 8 16 x 1 25 25 ft lbs 300 in lbs 17 200 1 3 8 16 x 1 25 32 ft lbs 380 in lbs 21 250 1 1 4 7 16 14 x 1 50 41 ft lbs 490 in lbs 27 320 1 1 2 1 2 13 x 1 50 53 ft lbs 640 in lbs 35 420 2 1 2 13 x 1 50 61 ft lbs 730 in lbs 40 480 2 1 2 1 2 13 x 1 75 86 ft lbs 1030 in lbs 56 670 3 5 8 11 x 1 75 144 ft lbs 1730 in lbs 94 1130 3 1 ...

Page 32: ...TORS CODE 62 SET WRENCH TO NOMINAL TUBE OD BOLT SIZE BOLT TORQUE FT LBS BOLT TORQUE IN LBS ALUMINUM FT LBS IN LBS 1 2 5 16 18 x 1 25 17 ft lbs 200 in lbs 12 130 3 4 3 8 16 x 1 25 30 ft lbs 360 in lbs 20 240 1 3 8 16 x 1 25 46 ft lbs 550 in lbs 30 360 1 1 4 1 2 13 x 1 75 69 ft lbs 830 in lbs 45 540 1 1 2 5 8 11 x 2 25 125 ft lbs 1500 in lbs 82 980 2 3 4 10 x 2 75 209 ft lbs 2510 in lbs 136 1640 ...

Page 33: ...ctions through ten 10 cycles while the engine idles See the Operator s Manual for operation instructions 6 Make sure the oil temperature on the site gauge is between 120 and 160 F If not repeat step 5 7 Check for fluid leaks Repair if necessary 8 The unit is now ready to go on route BATTERY DISCONNECT SWITCH The battery box is typically located on the streetside of the chassis frame near the front...

Page 34: ... the temperature changes DO NOT strike switch to make it work DO NOT damage the switch when you adjust it DO NOT adjust switch too close to the metal it is sensing Voltage spikes from truck chassis electrical system will break down the internal electronics of the proximity switch 1 Make sure the power source from the chassis manufacturer is clean 2 The body electrical system is protected from volt...

Page 38: ...dry with a micro fiber cloth Do not allow fuels to stay in contact with the decal for an extended period of time Remove the fuel contamination as quickly as possible Do not use carnauba based wax over the decals Do not use a mechanical brush while washing the decals B Pressure Washer Precautions Pressure washing can cause damage to decals It can cause the edges of the decals to lift and peel the d...

Page 39: ...Issued May 2020 General Information Copyright 2020 Heil Environmental Printed in the U S A General Information 33 DECAL CARE CONTINUED Figure 5 Recommended Technique Figure 6 Incorrect Technique ...

Page 44: ...e under the following conditions Condition 1 on route operation ON with Pump Control Enabled AND Engine Speed 900rpm AND Body Hoist Down AND Vehicle Road Speed 7mph default AND Service Brake applied Condition 2 stationary operation ON with Pump Control Enabled AND Engine Speed 900rpm AND Body Hoist Down AND Vehicle Road Speed 7mph default AND Transmission in Neutral Condition 2 stationary operatio...

Page 45: ...oaders Recycle 2000 and Liberty Figure 7 Tandem O I G A I Pump Figure 8 This is the Hydraulic Controls Operate In Gear At Idle OIGAI System The pump section pump 1 closest to the input shaft operates the lift and shuts off first The pump section pump 2 farthest from the input shaft operates the packer and stays on at higher RPMs ...

Page 46: ...alfunction in the unloader valve assembly Internal problem with the pump Perform the following test after finding that there is insufficient or no flow to the loader and or body valves 1 Check the Electrical Supply to the Unloader Valve Coils a With the system turned on and the engine operating at idle test the voltage at the coil It should read a minimum of 10 VDC If proper voltage is present and...

Page 47: ...ight 2020 Heil Environmental Printed in the U S A Pumps 41 TANDEM VANE PUMP O I G A I HYDRAULIC SYSTEM TROUBLESHOOTING CONTINUED NOTICE If flow is present check the main relief valves for proper adjustment and operation Figure 9 ...

Page 51: ...vel 2 48 X 14 48 Stroke B Body Main Relief 2500 PSI CNrG Tailgate Raise 1500 PSI Top Door or Hopper Cover 1500 PSI C Lift Valve Main Relief Valve Pressure 2300 PSI Reach In Out 2500 1250 PSI Reach Relief In Out 2500 1250 PSI Arm Up Down 2500 1250 PSI Packer Pressure Switch 2200 PSI D Grabber Relief 1250 1250 PSI E Cycle Times Lift Cycle Time Standard Python 7 9 Seconds Packer Cycle Time 12 16 Seco...

Page 52: ...l parts without fittings every 60 days with non detergent engine oil NOTICE If a grease zerk is missing or damaged replace as necessary Figure 11 Python Lift Lubrication Guide REF NO DESCRIPTION QTY FREQUENCY 1 Reach Pivot Link 4 Every 20 Hours 2 Rocker Assembly 1 Every 20 Hours 3 H Beam Assembly 6 Every 20 Hours 4 Level Link 2 Every 20 Hours 5 Reach Cylinder 2 Every 20 Hours 6 Lift Cylinder 2 Eve...

Page 53: ...cle times includes grab lift lower and release 5 Check Mounts Weekly 40 hrs Make sure chassis rail is undamaged Make sure chassis bolts are present and tight Check brackets for cracks Make sure lift bolts are present and secure 6 Check Lift Mount Base Bolts Weekly 40 hrs Visually inspect mounting bolts for security and movement Check the nuts and bolts to make sure the weld is secure See Check Lif...

Page 54: ...Manual for replacement parts C Before Replacing Lift Mount Bolts 1 Visually inspect the lift mount bolts on both the street side and curb side See the illustration for locations 2 Make sure the bolts are secure and there is no movement 3 Make sure welded bolts do not have cracks 4 If any lift mount bolt is loose cracked or broken replace all bolts Use only the parts specified Lower grade parts are...

Page 55: ...d corner to the second mark at the center of the fourth nut flat It is critical that the head of the bolt is held in place and not allowed to rotate further Brace the wrench handle as necessary 8 Weld the nut to the bolt as specified Welding the nut prevents the nut from loosening and prevents the bolt and nut from being reused 9 Do not remove paint marks Figure 14 Lift Mount Bolt Location Figure ...

Page 56: ...r arm and the outside roller is 30 1 See illustration below NOTICE The grabber belt holes on the inside end of the belt are farther apart to make longer adjustments The holes on the outside end of the belt are closer together to make shorter adjustments NOTICE When the grabbers are used with the Python Lift adjust the outer rollers so that they do not touch each other when the grabbers are complet...

Page 57: ...to obtain a firm grip for smaller containers The total overall length of the grabber belt must be set to obtain a firm grip for larger containers See illustration below NOTICE Do not adjust the total overall belt length too far as this may cause the grabber belt to touch or wear against the outer arm NOTICE When used with the Python lift the grabbers should be adjusted so the outer rollers do not ...

Page 58: ...abbers Adjust the grabber belt length so the distance between the roller on the inner arm and the outside roller is 30 1 See illustration below NOTICE The grabber belt holes on the inside end of the belt are farther apart to make longer adjustments The holes on the outside end of the belt are closer together to make shorter adjustments Figure 18 30 110 Gallon Tri Cuff Belt Grabbers ...

Page 59: ...bers open proximity switch should be adjusted so that it is activated when the grabbers are fully open To make adjustments to the lift stowed lift in proximity switch you will need a 7 16 wrench The lift stowed proximity switch should be adjusted so that it is activated when the lift arm is fully stowed or retracted See the figure below Watch the Preventive Arm Lift Maintenance video on the Heil S...

Page 60: ...VALVE Some key areas are shown below on the standard lift control valve The Python Lift uses a precision machined parallel control valve that does not have interchangeable spools Each spool is matched to the individual bore See Lift Control Valve Pressure Adjustments Figure 20 Python Lift Control Valve 55 ...

Page 61: ...ear the area of all unnecessary people before you operate the controls WARNING The hydraulic fluid may be under pressure and may spray while you open the connection Hydraulic fluid may cause damage to your eyes hands or skin Wear protective eye glasses gloves and other clothing as necessary to protect you from the hydraulic fluid NOTICE This procedure requires two properly trained technicians Befo...

Page 62: ...tments 1 Connect a 0 5000 psi pressure gauge to the gauge port on the inlet of the valve See the image below Figure 21 Inlet Section Pressure Gauge Port Figure 22 Seven Python Valve Pressure Settings LIFT CONTROL VALVE RELIEF PRESSURE SETTINGS PSI LIFT MAIN RELIEF LIFT UP RAISE DOWN LOWER GRABBER OPEN CLOSE LIFT IN RETRACT OUT EXTEND 2300 2500 1250 1250 1250 2500 1250 ...

Page 63: ...y one 7 To make adjustments to the lift lower or lift raise port relief valves you will need to loosen the jam nut with a 15 16 wrench Then make the adjustment with a slotted socket bit or a large slotted screwdriver 8 To make pressure adjustments to the lift extend lift retract grabber open or grabber close port relief valves you will need to loosen the jam nuts with a 7 16 wrench Then make the a...

Page 64: ...h 1 10 C clamp 1 1 1 2 steel rod 1 2lb hammer Plastic ties B Replace Grabber Arm Replacing the grabber beam requires two people To replace the beam complete the following steps 1 Use the 3 4 wrench and the impact wrench with the 3 4 socket to remove the bolts that connect the grabber arm to the grabber gear assembly 2 Disconnect the grabber proximity switch cable Use plastic ties to tie the cable ...

Page 65: ...aps to cap off the hydraulic fittings and hoses 9 Use the plastic ties to tie the hydraulic hoses out of the way 10 Support the grabber arm assembly and use the C clamp to secure the arm assembly to the support In the Figure below the arm assembly is supported by a fork lift Figure 25 Secured Grabber Arm 11 Remove the grabber level pin 12 Use the 1 1 2 steel rod and the 2 lb hammer to remove the g...

Page 66: ...d the relief pressure 4 Make sure the hydraulic oil tank is full 5 Start the unit 6 Activate and hold the hydraulic function that activates the hydraulic relief circuit to heat the oil a Units with Shur Lock systems must use the tailgate lock function b Rear loaders must use the ejector retract function 7 Every two minutes cycle the ejector cylinder function to mix the hot oil 8 Continue steps 6 a...

Page 67: ...rm Follow these welding requirements for repairing the lift arm 1 All material shall be free from paint soil grease dirt and any other non metal contamination 2 Weld according to the Weld Procedure 3 All welds shall be in conformance of AWS D1 1 4 Inspection supervisor required 5 Attach the ground lead as close as practical to the section where you are working Disconnect the battery negative or gr...

Page 68: ...y 2020 Lift Arm Copyright 2020 Heil Environmental Printed in the U S A Lift Arm 62 LIFT CONTROL PNEUMATIC INSTALLATION WITH AUTOLIFT FUNCTION Use the following illustration to troubleshoot the Autolift function ...

Page 70: ...dy and Tailgate Copyright 2020 Heil Environmental Printed in the U S A Body and Tailgate 64 NOMENCLATURE The following picture shows the major components and their typical location on the unit Figure 26 Body Nomenclature ...

Page 71: ... Valve Pressure Adjustments and Relief Valve Adjustment pages for valve adjustment procedures Valve Pressure Settings Loader Main Systems 2300 PSI Loader In Out Cross Port Relief 2500 1250 PSI Body Main Relief Valve 2400 PSI Packer Pressure Switch 2200 PSI Cycle Times Packer Cycle Empty Hopper 16 GPM 180 Sweep 13 16 Seconds NOTICE Check the lift mount bolts every 40 hours weekly for tightness 55 6...

Page 72: ...onmental Printed in the U S A Body and Tailgate 66 BODY PROPS The factory supplied body props are located on both sides under the body and forward of the rear wheels Refer the figure below Follow these steps to lower the body props Figure 27 Factory Body Props ...

Page 74: ...0 50 PSI To adjust the packer pressure switch setting follow these steps 1 With the engine off install an accurate 0 5000 PSI gauge in the quick disconnect port 2 Lower the body main relief valve 2200 PSI 50 See Body Main Relief Adjustment for proper procedure 3 Lower the packer pressure switch setting to 2200 PSI by turning the adjustment switch twice 4 With the engine running se the Auto Manual ...

Page 75: ...lic oil tank is full 5 Start the unit 6 Activate and hold the hydraulic function that activates the hydraulic relief circuit to heat the oil Units with Shur Lock systems must use the tailgate lock function Rear loaders must use the ejector retract function 7 Every two minutes cycle the ejector cylinder function to mix the hot oil 8 Continue steps 6 and 7 until the oil temperature thermometer on th...

Page 76: ...PUMP SETUP This hydraulic system is used with a tandem pump set up The system is activated by energizing pump solenoid A This solenoid is normally open and blocks closes the unloader system pressure when it is energized Pump solenoid B is mounted directly on the hydraulic pump See pump photo page Figure 29 Lift Control Valve for Liberty with Tandem Pump ...

Page 77: ... normally closed N C switch and is mounted on a bracket off the right rear hinge plate It is activated by making contact with the lower flange of the body long member This switch limits how high the body will raise by interrupting the power to the UP solenoid on the body packer valve This switch should be activated before either body hoist cylinder bottoms out or before the body exceeds a 40 degre...

Page 78: ...ing the operator that the tailgate is not fully closed and latched CAUTION If the tailgate unlatch limit switch does not activate the alarm DO NOT operate the truck Further troubleshooting is required PACKER REVERSING LIMIT SWITCH N C The Packer Reversing Limit Switch N C is non adjustable located under the body behind the packer actuator plate This switch is used to signal when to reverse the dir...

Page 79: ...oller and all other electronic control units ECUs If welding within 24 inches of a proximity switch remove the switch from the unit NOTICE Failure to follow these procedures may cause damage to the devices The damage comes from the inability of the devices to withstand the amperage open circuit voltage and magnetic flux a welder can produce Electrical Anti Corrosion Lubricant It is very important ...

Page 82: ...ardware Replace missing hardware immediately Damaged decal or decal not readable Replace decal immediately Low level of hydraulic oil Fill the hydraulic oil tank immediately Worn or damaged hoses Replace immediately Leaks at cylinders hoses or fittings Tighten loose connection Loose or missing hardware Tighten loose connections Replace missing hardware Worn fiber guards Replace hoses fittings as n...

Page 83: ... valve seals for leaks Repair or replace if necessary Replace filter after first 30 days of operation then every 6 months or 1000 hours of operation OR when filter bypass light is ON Replace tank breather filter every time you replace filter element Drain flush and refill Change filter element Electrical Battery Cables Check for proper operation Check battery cables from battery to starter for loo...

Page 84: ...78 BODY PREVENTIVE MAINTENANCE CHART HOURS OF OPERATION COMPONENT SYSTEM 8 40 200 1000 2000 CHECK SERVICE Grease Fittings Lubricate as shown on Body Lube Chart Body Undercoating Inspect body undercoating and repair as necessary Tailgate Seal Integrity Daily 8 hrs Weekly 40 hrs Monthly 200 hrs 6 Months 1000 hrs Yearly 2000 hrs ...

Page 85: ...enance and Adjustment 79 BODY LUBRICATION GUIDE Clean fittings before applying grease and always pump enough grease into joint to remove the old grease Wipe off excess grease Lubricate moveable mechanical parts without fittings every 60 days with non detergent engine oil Figure 30 Body Lubrication Guide ...

Page 86: ...age and two behind the left frame rail to lubricate the bearings at each end of the packer shaft Each injector takes approximately 800 PSI to open and stores about 0 15cc of grease for each pin The grease moves in each lube point through small nylon lines and a fitting to the pin surface It is important to inspect the system frequently Without lubrication the pins and bearings will wear very quick...

Page 87: ...in a number of ways 1 With the packer in MANUAL mode to operate the tailgate engine off but ignition switch on hold down the tailgate down control While the valve is trying to lower the tailgate the oil can flow out of the cylinder through the valve and into the tank 2 With the engine off but ignition switch on and the PTO engaged place a jumper wire from tailgate down to the TO in the lower junct...

Page 88: ... following position with all cylinders collapsed Truck on level ground Tailgate and Body fully down and locked Packer Panel in the in transit position with all cylinders retracted Lift Arm if equipped is fully retracted The oil tank is mounted behind the chassis cab The oil level in the standard tank must be kept between the low and full marks as indicated on the sight gauge See the figure below F...

Page 89: ...lement from your local Heil distributor Change the filter element when oil analysis shows the oil has expired CHANGE HYDRAULIC OIL FILTER ELEMENT Watch the Service Shack Video online at www Heil com Heil Service Shack and selecting Changing Filters Replace the hydraulic filter element after first 30 days of operation then every 6 months or 1000 hours of operation OR when filter bypass light is ON ...

Page 90: ...in or on the body or on equipment can cause serious injury or death NOTICE If your employer or company has Lock Out Tag Out procedures that are different from the following procedures use your employer s or company s procedures If your employer or company does not have Lock Out Tag Out procedures use the procedures that follow 2 Contact your supervisor if you have any questions about Lock Out Tag ...

Page 91: ...echanism 18 Operate tailgate full up and full down 19 Operate body raise dump units full up and full down 20 With the packing panel in the retracted position and lift in the in transit position check tank oil level If necessary add recommended as described under Check Oil Level PURGE THE HYDRAULIC SYSTEM If the hydraulic system becomes contaminated because of component failure or some other reason...

Page 92: ... 2020 Heil Environmental Printed in the U S A Maintenance and Adjustment 86 PACKER BODY VALVE The packer valve is located between the chassis rails and controls the packer panel left and right movements body raise lower and tailgate raise lower functions ...

Page 93: ... soon as possible Tailgate or body raise operates Check for wiring bad coil or bad solenoid blocker valve 4 Tailgate or body raise doesn t operate Start truck again and run BRIEFLY to operate manual overrides on tailgate or body raise valve Shut truck down as soon as possible Tailgate or body raise now moves Check for wiring coil or controller problem Tailgate doesn t move Replace logic valve 3 Pa...

Page 94: ...ION Use a grease gun Before engaging grease gun clean the fitting Always pump enough grease to purge the joint of contaminated grease and wipe off the excess Lubricate a unit as given on the lubrication decal on the unit and in the Body Lubrication Guide paragraph of this section Use grade NLG1000 grease or equivalent TAILGATE LUBRICATION See Grease Lubrication Recommendation and Body Lubrication ...

Page 96: ...the relays that control the hoist raise lower and tailgate raise lower LED COLOR STATUS DESCRIPTION N A OFF No Supply Voltage Red Green 1 Flash Initialization Red Green Flash 5 Hz Communications Lost Green Flash 5 Hz No Operating System Loaded Green Flash 2 Hz Application Running RUN MODE Green Continuous Application Stop STOP MODE Red Flash 5 Hz Supply Voltage Low Red Flash 10 Hz Fatal Error Figu...

Page 97: ...ody harness near the Connector D1 FUSE AMPERAGE CIRCUIT F1 20A Body Controller Power Pin10 Cab Controller Power Pin10 Switch Banks System Power Input Auxiliary Control Lift Control Sensor Power F2 15A Cab Controller Output Power 08 15 Pin1 F3 15A Body Controller Output Power 00 07 Pin19 Body Valve Relay Output Power F4 15A Cab Controller Output Power 00 07 Pin19 Body Controller Output Power 08 15 ...

Page 100: ...is J1939 interface There are three discrete networks in the system CAN1 Network Communications between the Body Controller Cab Controller and Insight Display DEV J1939 Network Communications between the Body Controller and switch banks or other devices that may be added CH J1939 Network Communications between the Cab Controller and the truck chassis J1939 Baud Rates The baud rate setting determine...

Page 101: ...P IN05 34 HOPPER COVER PROX IN06 52 SIDE DOOR PROX IN07 33 TAILGATE CLOSED PROX IN08 24 BODY DOWN PROX IN09 41 PACKER PROX IN10 23 SPARE IN11 40 BODY RAISE LIMIT SW IN12 22 FILTER PRESS SW IN13 39 LOW OIL SW IN14 21 LIFT RETRACTED PROX IN15 38 GRABBER OPEN PROX VBBS 10 SUPPLY VOLTAGE CONTROLLER VBB1 19 SUPPLY VOLTAGE OUTPUT 00 08 VBB2 1 SUPPLY VOLTAGE OUTPUT 08 15 N A N A CONTROLLER TEMP N A N A C...

Page 102: ...N04 53 TURN SIG IN05 34 SERVICE BRAKE IN06 52 SPARE IN07 33 NEUTRAL SIG IN08 24 SYSTEM POWER SW IN09 41 PUMP ENABLE PB IN10 23 GRABBER CLOSE PB IN11 40 GRABBER OPEN PB IN12 22 ENGINE TACH SIG NOT USED IN13 39 SPARE IN14 21 SPARE IN15 38 SPARE VBBS 10 SUPPLY VOLTAGE CONTROLLER VBB1 19 SUPPLY VOLTAGE OUTPUT 00 08 VBB2 1 SUPPLY VOLTAGE OUTPUT 08 15 N A N A CONTROLLER TEMP N A N A CAN OPEN CYCLE TIME ...

Page 103: ...BLE SW1 MANUAL PACK SW1 AUTO LIFT ENABLE SW1 STROBE ENABLE SW1 WORK LIGHT SW1 PACK RIGHT SW1 PACK LEFT SW1 BODY RAISE SW1 BODY LOWER PSW1 TG RAISE SW1 TG LOWER SW1 PUMP ENABLE SW2 MANUAL PACK SW2 AUTO LIFT ENABLE SW2 STROBE ENABLE SW2 WORK LIGHT SW2 PACK RIGHT SW2 PACK LEFT SW2 BODY RAISE SW2 BODY LOWER PSW2 TG RAISE SW2 TG LOWER SW2 Figure 38 Switch Bank Inputs ...

Page 104: ...REVERSE GEAR ON TRANSMISSION IN REVERSE GEAR NEUTRAL ON TRANSMISSION IN NEUTRAL TRANS PTO CONSENT ON TRANSMISSION CONSENT TO ENGAGE HOT SHIFT PTO LEFT TURN ON LEFT HAND TURN SIGNAL IS ACTIVE RIGHT TURN ON RIGHT HAND TURN SIGNAL IS ACTIVE ENGINE RPM DISPLAYS ENGINE SPEED rpm ENGINE TORQUE DISPLAYS ENGINE PERCENT TORQUE ROAD SPEED DISPLAYS VEHICLE SPEED mph AMBIENT TEMP DISPLAYS CURRENT AMBIENT TEMP...

Page 105: ...ply Voltage is too high Settings Invalid Program Error Wire Break Open Circuits Detected Short Circuit Short Circuit Detected Over Current Overload on Circuit Diagnostic features outputs 08 thru 15 Disabled Output is disabled by option set or spare OUTPUT PIN DESCRIPTION OUT00 18 HOPPER COVER OPEN OUT01 17 HOPPER COVER CLOSE OUT02 16 BODY RAISE SOL OUT03 15 BODY LOWER SOL OUT04 14 TG RAISE SOL OUT...

Page 106: ...age is too high Settings Invalid Program Error Wire Break Open Circuits Detected Short Circuit Short Circuit Detected Over Current Overload on Circuit Diagnostic features outputs 08 thru 15 Disabled Output is disabled by option set or spare OUTPUT PIN DESCRIPTION OUT00 18 GRABBER CLOSE SOL OUT01 17 GRABBER OPEN SOL OUT02 16 PTO SOL OUT03 15 PUMP1 SOL OUT04 14 PUMP2 SOL OUT05 13 LIFT ENABLE SOL OUT...

Page 107: ...ed Screens Maintenance Screen 4321 Option Settings Screen 123412 Figure 42 Password Protected Screens MAINTENANCE SCREEN Service Mode is strictly intended to allow movement of the lift or packer blade while servicing or troubleshooting the unit Service Mode overrides all interlocks and disables all automated operation of the Packer and Lift Daily Pack Cycle count reset with OK button Daily Arm Cyc...

Page 108: ...enting grabber from opening with the lift raised Requires additional hardware to determine lift raised position Lift Raise lock On Off ON Enables interlock preventing lift from raising with grabber open Requires additional hardware to determine lift raised and grabber closed Hyd Hopper Cover On Off ON Enables circuits for optional hydraulic hopper cover Only used when Hydraulic Hopper option in in...

Page 109: ...ssed from the Main screen by using the down directional arrow this screen shows the status of all critical faults Press escape button to exit Figure 45 Critcal Faults Accessed from the Critical Faults screen by using the right directional arrow this screen shows the status of all system faults Press escape button to exit Figure 46 System Faults ...

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Page 115: ...2 15 2018 Rev A2 ...

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Page 125: ...ASSY STRAINER ASSY BODY CYLINDER HYDRAULIC TANK CYLINDER DRAIN VALVE TO LOADER PACKER CYLINDER PACKER LEFT P G C D B A VB PS VA T PACKER TAILGATE BODY RAISE 701 8394 B BLOCKER SOLENOID LOGIC VALVE PUMP PRESSURE RETURN PRESSURE LEGEND ...

Page 126: ...ASSY STRAINER ASSY BODY CYLINDER HYDRAULIC TANK CYLINDER DRAIN VALVE TO LOADER PACKER CYLINDER PACKER RIGHT P G C D B A VB PS VA T PACKER TAILGATE BODY RAISE 701 8394 A BLOCKER SOLENOID LOGIC VALVE LEGEND RETURN PRESSURE PUMP PRESSURE ...

Page 127: ...RAINER ASSY BODY CYLINDER HYDRAULIC TANK CYLINDER DRAIN VALVE TO LOADER PACKER CYLINDER TG LOWER P G C D B A VB PS VA T PACKER TAILGATE BODY RAISE 701 8394 C BLOCKER SOLENOID LOGIC VALVE PUMP PRESSURE RETURN PRESSURE METERED PRESSURE LEGEND ...

Page 128: ...RAINER ASSY BODY CYLINDER HYDRAULIC TANK CYLINDER DRAIN VALVE TO LOADER PACKER CYLINDER TG RAISE P G C D B A VB PS VA T PACKER TAILGATE BODY RAISE 701 8394 D BLOCKER SOLENOID LOGIC VALVE PUMP PRESSURE RETURN PRESSURE METERED PRESSURE LEGEND ...

Page 129: ...AINER ASSY BODY CYLINDER HYDRAULIC TANK CYLINDER DRAIN VALVE TO LOADER PACKER CYLINDER BODY RAISE P G C D B A VB PS VA T PACKER TAILGATE BODY RAISE 701 8394 E BLOCKER SOLENOID LOGIC VALVE PUMP PRESSURE RETURN PRESSURE METERED PRESSURE LEGEND ...

Page 130: ...RAINER ASSY BODY CYLINDER HYDRAULIC TANK CYLINDER DRAIN VALVE TO LOADER PACKER CYLINDER BODY DOWN P G C D B A VB PS VA T PACKER TAILGATE BODY RAISE 701 8394 F BLOCKER SOLENOID LOGIC VALVE PUMP PRESSURE RETURN PRESSURE METERED PRESSURE LEGEND ...

Page 133: ...rosion lubricants 73 electrical symbols 36 electronic controls lubricants 73 Electronic Parts Catalog EPC registration and login 8 search by body serial number 8 search by part keyword in body serial number 8 F flow diagram lift arm down 117 flow diagram lift arm grab 114 flow diagram lift arm reach in 115 flow diagram lift arm reach out 116 flow diagram lift arm release 113 flow diagram lift arm ...

Page 134: ...t nomenclature 44 python lift specifications 45 R recommended spare parts 6 remove grabber beam assembly 58 repairing cracked weld joints 88 S service parts assistance 5 specifications 65 standard torque data for nuts and bolts 17 standard torque data for nuts and bolts table 17 storing refuse in the body 16 switch bank inputs 97 T tailgate lubrication 88 tailgate support props 67 tailgate unlatch...

Page 135: ...Customer Service Department within sixty 60 days of the equipment s In Service date Wear items are excluded from warranty coverage All OEM service parts sold by Heil have a six 6 month warranty from the date of purchase Aftermarket parts purchased from Heil are supported by a 90 day warranty The parts warranty covers parts only providing that factory inspection reveals a defect in material or work...

Page 136: ...ww heil com Customer Care 866 ASK HEIL 866 275 4345 Heil Environmental 4301 Gault Avenue North Fort Payne AL 35967 9984 Parts Central 800 528 5308 Technical Service 866 310 4345 TechSupport DoverESG com ...

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